JayBaima

In processes where variable speed is not an absolute necessity, but where users are concerned about energy savings and the impacts on electrical and mechanical systems of full-voltage starting, the choice between a variable speed drive (VSD) and a reduced voltage (i.e. “soft”) starter can be a difficult one. There are a number of factors which should be considered when making this choice. Several of these factors are described below, together with recommendations for the starting/control method to be used.

• Overall system design efficiency: consider two piping systems: one sized to utilize pumps designed to operate at their “best efficiency point” (BEP); and one designed and built with excess capacity available, perhaps for future expansion. In the former instance, regulating process flow by controlling motor speed will typically not lead to enhanced process efficiency, and choosing a  VSD which will only serve to operate its motor at base (rated) speed will not gain you much in terms of energy use, either. However, a system built with excess capacity will typically suffer in efficiency when that capacity is not needed, so regulating process output by reducing pump speed may actually enhance efficiency, and can certainly reduce […]

Please note: the following information is derived from the NEMA MG 1-2007 condensed standard. More information, as well as the full NEMA MG 1 standard, can be found at www.NEMA.org.

When applying adjustable speed drives for the control of induction motors, several operating impacts should be considered in order to ensure proper operation and equipment life. What follows is a brief overview of some common considerations:

• Motor torque, speed, and temperature: Many modern adjustable speed drives (ASD’s) are capable of controlling torque by directly manipulating motor flux, such that torque is maintained constant across the full zero-to-base speed range. That said, when operating a self-cooled motor at reduced speeds, temperature rise must be factored in. This means that in many cases it is advisable to de-rate a self-cooled motor to ensure temperature rise is maintained within the range dictated by insulation classification. It is generally stated that each increase of 10 degrees Celsius in winding temperature above rated levels reduces winding insulation life by 50%, so proper cooling is essential. In addition to de-rating, there are several other ways to address this issue, including auxiliary cooling (such as […]

Editor’s Note: Much of the information which follows is taken from engineering information provided by Siemens AG in their “Sinamics DCM Converter Units” catalog D 23.1 – 2010. The Sinamics DCM is the line of industrial DC drives in the Sinamics family, which forms a part of Siemens’ “Totally Integrated Automation” concept; learn more at www.siemens.com. However, the concepts discussed herein can generally be applied to any drive application.

Because of the high switching frequencies of their electronic components, variable speed drives are by their nature radiating devices. This radiated energy is termed electromagnetic interference (EMI); measures to reduce EMI during design and installation are intended to ensure electromagnetic compatibility (EMC), which is essentially the ability of a device to function satisfactorily in an electromagnetic environment without itself causing interference unacceptable to other devices in the environment.

In the typical industrial environment, EMI occurs in the range of 150kHz – 30 MHz and can have adverse consequences on the operation of nearby sensitive equipment. When considering measures to ensure EMC, the drive must be looked at as forming part of a system, the other components being minimally the cables and […]

Many of you have written in with questions regarding installation methods, drive technologies, operating parameters, and other issues. Since it is often time-prohibitive to respond individually to all of them, I thought I would consolidate and address some of the more common – and commonly applicable – questions that have been submitted.

• “Does the wiring between the VFD and motor require special cabling?
  Can we just use standard 600V wiring such as THHN, THWN, etc.?
  We come across cables that are noted as “VFD rated”. Are these cables required for all VFD installations?”

Drive manufacturers typically recommend shielded, symmetrically constructed cables to reduce the impacts of electromagnetic interference and capacitive coupling. In cases where compliance with European (CE) electromagnetic compatibility is required, these types of cables, properly installed and bonded, are mandatory. Where EU compliance is not a concern, the suitability of the cable used will depend on several factors, including cable length, sensitivity of nearby components and equipment to radiated interference, motor size, and installation methods. Typically, motors rated less than 40 hp, and less than about 100′ of lead length (per phase), can be fed with 600V single conductor […]

Modern variable speed drives (VSDs) are equipped with a multitude of features to provide programming flexibility, enhance efficiency and increase the accuracy of control. Let’s dissect some of these features, typified in this case by the A1000 series of industrial AC drives from Yaskawa (www.yaskawa.com).

Control methods: the A1000 provides up to seven different control methods to suit specific motors and applications. Methods range from basic scalar (volts/hertz, or V/f) control, which adjusts frequency and voltage output in direct proportion based on command reference, through open-loop vector control, to closed loop vector control. Vector control essentially “splits” the stator current into separate torque and field components, analogous to the separate armature and field components of a DC motor, and controls VSD output by regulating voltage magnitude, angle of displacement, and frequency. In open loop systems, modeling is used to calculate vectors and adjust output based on measured output current, while in closed loop configuration, sensors such as encoders or tachometers directly measure rotor position and speed and are able to control output even more tightly. In the A1000, V/f control can provide a typical speed control range of 40:1, while open-loop vector can achieve 200:1 […]

Much has been discussed of the additional stresses that variable speed drives (VSD’s) can place on motor leads and insulation systems. However, in all but the most sensitive of installations, and assuming the use of properly rated motors, preventive or corrective measures are readily applied, especially during design and engineering stages. While each VSD and motor manufacturer has specific requirements for cabling design and installation practices, there are several elements common to all.

• Limiting motor lead length: by installing drives as close as practical to the motors they control, the magnitude of voltage overshoot is reduced, lessening the risk of over-voltage at the motor terminals (all other things being equal). There is a length, generally referred to as the critical length, beyond which the magnitude of reflected voltage pulses increases to the the extent that motor insulation systems can be affected. Critical length varies based on cable and drive characteristics and is calculated as:

The critical length is a consequence of the rate of travel of the pulse from the […]

At Joliet Technologies, one of  our strongest markets is the direct current (DC) motor and motor controls field. There remain a significant number of DC motor applications in the utilities, transportation, and manufacturing sectors, including among others the oil, pulp and paper, metals, and automotive industries. While many are familiar with typical alternating current (AC) variable frequency drives, DC drive applications are less common. However, the basic operating concepts share some common elements. Let’s examine DC drive basic operating principles in more detail. Some of the information which follows is excerpted from Siemens online training, which can be accessed here: Siemens Online Motors and Control Courses.

Most commonly, DC drives are used to regulate the speed of shunt wound or permanent magnet DC motors. In larger motor applications typical to industry shunt wound motors are used, and we will refer to those for purposes of this discussion. In shunt wound motors, the stator pole pieces are electromagnets wired in parallel with the armature (rotor) windings. Typically, voltage is supplied to the stator poles via a separate source of supply (referred to as a field exciter). This creates a magnetic field, called a shunt field, […]

As many of you realize, modern pulse-width modulated (PWM) variable frequency drives (VFD’s) can place added stresses on motor insulation systems, particularly in older motors in drive retrofit applications. Let’s examine this type of application in greater detail to understand causes and discuss preventive and corrective measures.

VFD’s output synthesized AC waveforms, consisting of rapid rise-time pulses of varying width (hence the term “pulse-width modulated”). These pulses are generated by the switching “on” and “off” states of the drive output electronics, typically insulated gate bipolar transistors (IBGTs). Each time one of the IGBTs switches on, the output voltage from that device rises rapidly, over-shoots the nominal voltage value, and then settles back down to nominal, which is the rectified DC voltage produced in the drive’s converter stage. This switching on and overshoot happens very rapidly; the “rise time”, defined in NEMA MG-1 as the time required for the voltage to rise from 10% to 90% of DC link voltage, is in the neighborhood of 0.1 microseconds. Rise time is referred to as “dV/dt”, short-hand for the instantaneous rate of change of voltage with respect to time, and the formula is: